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Modelling and Optimization of Machining of Ti-6Al-4V Titanium Alloy Using Machine Learning and Design of Experiments Methods

Authors :
José Outeiro
Wenyu Cheng
Francisco Chinesta
Amine Ammar
Source :
Journal of Manufacturing and Materials Processing, Vol 6, Iss 3, p 58 (2022)
Publication Year :
2022
Publisher :
MDPI AG, 2022.

Abstract

Ti-6Al-4V titanium is considered a difficult-to-cut material used in critical applications in the aerospace industry requiring high reliability levels. An appropriate selection of cutting conditions can improve the machinability of this alloy and the surface integrity of the machined surface, including the generation of compressive residual stresses. In this paper, orthogonal cutting tests of Ti-6Al-4V titanium were performed using coated and uncoated tungsten carbide tools. Suitable design of experiments (DOE) was used to investigate the influence of the cutting conditions (cutting speed Vc, uncut chip thickness h, tool rake angle γn, and the cutting edge radius rn) on the forces, chip compression ratio, and residual stresses. Due to the time consumed and the high cost of the residual stress measurements, they were only measured for selected cutting conditions of the DOE. Then, the machine learning method based on mathematical regression analysis was applied to predict the residual stresses for other cutting conditions of the DOE. Finally, the optimal cutting conditions that minimize the machining outcomes were determined. The results showed that when increasing the compressive residual stresses at the machined surface by 40%, the rake angle should be increased from negative (−6°) to positive (5°), the cutting edge radius should be doubled (from 16 µm to 30 µm), and the cutting speed should be reduced by 67% (from 60 to 20 m/min).

Details

Language :
English
ISSN :
25044494
Volume :
6
Issue :
3
Database :
Directory of Open Access Journals
Journal :
Journal of Manufacturing and Materials Processing
Publication Type :
Academic Journal
Accession number :
edsdoj.f22e209d58074d41b2fcff7bbbc37ba8
Document Type :
article
Full Text :
https://doi.org/10.3390/jmmp6030058